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WEDM of tapered rectangular geometry in tungsten–carbide cobalt composite (WC–Co): geometrical errors and surface roughness analysis

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Abstract

Tungsten carbide cobalt composite (WC–Co) is frequently employed for tool and die making due to its superior mechanical properties; however, its high hardness and composite nature makes it a difficult-to machine material with conventional processes. This difficulty is further augmented when intricate and complex profiles are to be machined at high level of precision. Geometrical accuracy of these profiles has paramount importance as WC–Co tools have to generate the replica of their shape on workpiece. Wire electric discharge machining (WEDM) is capable of processing very hard materials, yet it has its own challenges related to geometrical accuracy and surface quality of machined parts which need to be investigated. In the present research work, WEDM has been employed for machining a very small-sized rectangular and tapered cavity in WC–Co. Six WEDM process parameters, namely open voltage (OV), pulse duration (PONT), pulse interval (POFFT), servo voltage (SV), wire tension (WT), and flushing pressure (DP), have been taken as input variables. The effect of WEDM parameters on geometrical errors at top and bottom surfaces (GETS and GEBS) of machined cavity and surface roughness (Ra) has been assessed by analysis of variance and main effect plots. Experimental results reveal that value of GETS is higher as compared to corresponding value of GEBS due to taper cutting. OV is the most influential parameter for GETS, GEBS, and Ra with a contribution of 48.4%, 20.4%, and 31.5%, respectively. GETS, GEBS, and Ra have shown a decreasing trend with increase in DP. GETS decreases with increase in PONT. Both GEBS and Ra tend to decrease with increase in SV. SEM images indicate that deposition of recast layer inside machined cavity and fractured layer due to cracking are potential sources of higher geometrical error. Single parametric optimization using S/N ratio method has resulted in improvement of 27%, 75%, and 16% for GETS, GEBS, and Ra, respectively. Moreover, application of gray relational analysis (GRA) technique leads to simultaneous optimization of all three responses with a reduction of 36.4%, 31.3%, and 12% in GETS, GEBS, and Ra, respectively.

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Authors and Affiliations

  1. Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890, Pakistan

    Rakhshanda Naveed & Kashif Ishfaq

  2. Massey Agrifood (MAF) Digital Labs, Massey University, Palmerston North, 4410, New Zealand

    Muhammad Harris

  3. Industrial Engineering Department, College of Engineering and Architecture, Al-Yamamah University, Riyadh, 11512, Saudi Arabia

    Naveed Ahmed

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  1. Rakhshanda Naveed
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  2. Kashif Ishfaq
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Naveed, R., Ishfaq, K., Harris, M. et al. WEDM of tapered rectangular geometry in tungsten–carbide cobalt composite (WC–Co): geometrical errors and surface roughness analysis. J Braz. Soc. Mech. Sci. Eng. 45, 67 (2023). https://doi.org/10.1007/s40430-022-03945-6

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